Balcony system and method

ABSTRACT

Systems and methods for balconies and false balconies are described.

RELATED APPLICATIONS

This application claims the benefit of U.S. Application No. 62/767,355,entitled “Balcony System and Method,” and filed on Nov. 14, 2018, whichis incorporated herein by reference in its entirety.

BACKGROUND

The construction industry is increasingly using modular constructiontechniques to improve efficiency. However, some aspects of construction,such as traditional balcony construction, may still present challengesto improving construction efficiency.

Workplace safety regulations, other rules, or industry practices mayrequire all personnel in a building (or area of a building underconstruction) that has a balcony opening but no balcony guardrailinstalled to wear safety harnesses, which may increase labor costs andreduce time efficiencies. Further, installation of traditional balconycomponents may be time consuming and require skilled tradespeople andspecialized equipment.

SUMMARY

Some implementations can include a balcony system, a false balconysystem, and methods for making and installing both. Some implementationscan include a balcony system having a balcony beam including a first endand a second end, wherein each of the first end and the second end areconfigured to attach to corresponding structural frame members of abuilding. The balcony system can also include a channel balcony frame,and a channel balcony frame attachment member attached to the balconybeam and having one or more apertures.

The balcony system can further include one or more reinforcement barsdisposed in an interior space defined by the channel balcony frame,wherein the one or more reinforcement bars extend through the one ormore apertures in the channel balcony frame attachment member, andwherein the reinforcement bars and the channel balcony frame attachmentmember are held in place within the interior space defined by thechannel balcony frame by a floor formed within the interior spacedefined by the channel balcony frame, such that, after the floor isformed, the balcony beam, channel balcony frame and concrete floor forman integral unit.

The balcony system can also include one or more guardrail supportbrackets attached to the channel balcony frame via one or more fastenersthat pass through the one or more guardrail support brackets and intothe interior space defined by the channel balcony frame, wherein the oneor more guardrail support brackets are secured in place by the floorformed within the interior space defined by the channel balcony frame.The balcony system can further include one or more stanchion guardrailsupports each attached to a respective one of the one or more guardrailsupport brackets and secured in place by a corresponding closure plate.

In some implementations, the balcony system can also include a guardrailattached to the one or more stanchion guardrail supports, one or morehorizontal guardrail members attached to the one or more stanchionguardrail supports, and one or more guardrail panels attached to the oneor more horizontal guardrail members.

In some implementations, each of the first end and the second end caninclude a respective plate to couple the balcony beam to thecorresponding structural frame members of the building. The channelbalcony frame can have a rectangular shape.

In some implementations, the channel balcony frame can include one ormore stanchion guard rail support apertures each configured to enable arespective stanchion guard rail support to pass through a respectivestanchion guard rail support aperture. The channel balcony frame can beformed from stainless steel and the balcony floor can be formed fromconcrete.

The balcony system can also include a light element coupled to the oneor more stanchion guardrail supports. In some implementations, the oneor more guardrail panels include one or more of tempered glass, metalmesh, polycarbonate, photovoltaic panels, or resin panels.

Some implementations can include a false balcony system having a balconybeam including a first end and a second end, wherein each of the firstend and the second end are configured to attach to correspondingstructural frame members of a building, and a balcony beam attachmentmember attached to the balcony beam such that the balcony beamattachment member and the balcony beam form an integral unit, whereinthe balcony beam attachment member includes one or more apertures. Thefalse balcony system can include one or more guardrail support bracketsattached to the balcony beam attachment member via one or more fastenersthat pass through the one or more guardrail support brackets and througha respective aperture in the balcony beam attachment member.

The false balcony system can also include one or more stanchionguardrail supports each attached to a respective one of the one or moreguardrail support brackets and secured in place by a correspondingclosure plate, and a guardrail attached to the one or more stanchionguardrail supports. The false balcony system can further include one ormore horizontal guardrail members attached to the one or more stanchionguardrail supports, and one or more guardrail panels attached to the oneor more horizontal guardrail members.

In some implementations, each of the first end and the second end caninclude a respective plate to couple the balcony beam to thecorresponding structural frame members of the building. The falsebalcony system can also include a light element coupled to the one ormore stanchion guardrail supports. The guardrail panels can include oneor more of tempered glass, metal mesh, polycarbonate, photovoltaicpanels, or resin panels.

Some implementations can include a method including forming a balconybeam having a first end and a second end, and forming a channel balconyframe. The method can also include forming a balcony beam attachmentmember, and attaching the balcony beam attachment member to the balconybeam. The method can further include attaching guardrail supportbrackets to the channel balcony frame, and forming a balcony floorwithin a space defined by the channel balcony frame to form an integralbalcony unit that includes the balcony beam, the channel balcony frame,and the balcony floor.

The method can also include providing the integral balcony unit andguardrail parts to a construction site of a building, wherein theguardrail parts include a guardrail and one or more stanchion guardrailsupports, and attaching the integral balcony unit to a structural frameof the building. The method can further include attaching the guardrailparts to the integral balcony unit, and attaching one or more guardrailpanels to the guardrail.

The method can also include attaching a respective plate to each of thefirst end and the second end of the balcony beam to couple the balconybeam to the structural frame of the building. Forming the channelbalcony frame can include forming the channel balcony frame in arectangular shape.

The channel balcony frame can include one or more stanchion guard railsupport apertures each configured a respective stanchion guard railsupport to pass through a respective stanchion guard rail supportaperture. Forming the channel balcony frame can include forming thechannel balcony frame from stainless steel. The guardrail panels caninclude one or more of tempered glass, metal mesh, polycarbonate,photovoltaic panels, or resin panels.

Some implementations can include a method comprising forming a balconybeam having a first end and a second end, and forming a balcony beamattachment member. The method can also include attaching the balconybeam attachment member to the balcony beam to form an integral balconyunit, and providing the integral balcony unit and guardrail parts to aconstruction site of a building, wherein the guardrail parts include aguardrail and one or more stanchion guardrail supports. The method canfurther include attaching the integral balcony unit to a structuralframe of the building, and attaching the guardrail parts to the integralbalcony unit. The method can also include attaching one or moreguardrail panels to the guardrail.

The method can also include attaching a respective plate to each of thefirst end and the second end of the balcony beam to couple the balconybeam to the structural frame of the building. The guardrail panels caninclude one or more of tempered glass, metal mesh, polycarbonate,photovoltaic panels, or resin panels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram showing a perspective view of an example balconysystem from a lower vantage point in accordance with some embodiments.

FIG. 2 is a diagram showing a side perspective view of an examplebalcony system in accordance with some embodiments.

FIG. 3 is a diagram showing a rear perspective view of an examplebalcony system in accordance with some embodiments.

FIG. 4 is a diagram showing a side sectional view of a guardrailconnection in accordance with some embodiments.

FIG. 5 is a diagram showing a top plan view of a guardrail connection inaccordance with some embodiments.

FIG. 6 is a diagram showing a front elevation view of a guardrailconnection in accordance with some embodiments.

FIG. 7 is a diagram showing a false balcony system in accordance withsome embodiments.

FIG. 8 is a diagram showing a balcony in accordance with someembodiments.

FIG. 9 is a diagram showing an example building with false balconies andbalconies in accordance with some embodiments.

FIGS. 10A, 10B, and 10C show elevation, plan and framing views,respectively, of an example studio unit balcony with metal infill inaccordance with some implementations.

FIGS. 11A, 11B, and 11C show elevation, plan and framing views,respectively, of an example studio unit balcony with metal infill inaccordance with some implementations.

FIGS. 12A, 12B, and 12C show elevation, plan and framing views,respectively, of an example studio unit balcony with metal infill inaccordance with some implementations.

FIGS. 13A, 13B, and 13C show elevation, plan and framing views,respectively, of an example one bedroom unit balcony with metal infillin accordance with some implementations.

FIGS. 13A, 13B, and 13C show elevation, plan and framing views,respectively, of an example one bedroom unit balcony with metal infillin accordance with some implementations.

FIGS. 14A, 14B, and 14C show elevation, plan and framing views,respectively, of an example one bedroom unit balcony with metal infillin accordance with some implementations.

FIGS. 15A, 15B, and 15C show elevation, plan and framing views,respectively, of an example one bedroom unit balcony with metal infillin accordance with some implementations.

FIGS. 16A, 16B, and 16C show elevation, plan and framing views,respectively, of an example one bedroom unit balcony with metal infillin accordance with some implementations.

FIGS. 17A, 17B, and 17C show elevation, plan and framing views,respectively, of an example two bedroom unit balcony with metal infillin accordance with some implementations.

FIGS. 18A, 18B, and 18C show elevation, plan and framing views,respectively, of an example two bedroom unit balcony with metal infillin accordance with some implementations.

FIG. 19 is a sectional view of an example balcony with metal infill inaccordance with some implementations.

FIG. 20 is a sectional view of an example balcony with metal infill inaccordance with some implementations.

FIG. 21 is a sectional view of an example balcony with metal infill inaccordance with some implementations.

FIG. 22 shows sectional details of an example balcony with metal infillin accordance with some implementations.

FIG. 23 is a flowchart of an example method to make and install abalcony system in accordance with some embodiments.

FIG. 24 is a flowchart of an example method to make and install a falsebalcony system in accordance with some embodiments.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative embodiments described in thedetailed description, drawings, and claims are not meant to be limiting.Other embodiments may be utilized, and other changes may be made,without departing from the spirit or scope of the subject matterpresented herein. The aspects of the present disclosure, as generallydescribed herein, and illustrated in the Figures, can be arranged,substituted, combined, separated, and designed in a wide variety ofdifferent configurations, all of which are implicitly contemplatedherein.

This disclosure is drawn, inter alia, to methods, systems, products,devices, and/or apparatuses generally related to a balcony including afull balcony and a false balcony (also known as a balconette or Frenchbalcony). As used herein, “balcony” may refer to both a balcony and/or afalse balcony as disclosed herein unless context dictates otherwise.

In some embodiments, a building may have one or more balconies. In someembodiments, when the building is being constructed, prefabricatedbalconies may be installed. The prefabricated balconies may provide aportion of an exterior surface of the building. In some embodiments, theprefabricated balconies may be coupled to one or more structural framemembers of the building. In some embodiments, the balconies may beattached to the structural frame members to help align the structuralframe members prior to exterior or interior wall panels being installed.In some embodiments, the balconies are coupled to a load-bearingstructure of the building. For example, the load-bearing structure maybe an external construction steel frame.

In some embodiments, one or more of the balconies may have lights orother utilities pre-installed. Utilities may include electrical,plumbing, heating and air conditioning, telecommunications, and/or otherutilities. Installing the lights or utilities during fabrication of thebalconies prior to delivery to a building construction site may allowfor faster assembly of the building and may reduce the number of skilledtradespeople required for installation of the balconies in the buildingin some embodiments.

In some embodiments, the balconies may include two types ofbalconies—full balconies and false balconies. In some embodiments, oneor more of the balconies may be configured to provide at least a portionof an exterior surface of the building.

In some embodiments, the material composition of the balcony may includesteel. In some embodiments, the material composition may includealuminum. In still other embodiments, the components of the balconysystem may be made from a variety of building suitable materials rangingfrom metals and/or metal alloys, to wood and wood polymer composites(WPC), wood based products (lignin), other organic building materials(bamboo) to organic polymers (plastics), to hybrid materials, or earthenmaterials such as ceramics. In some embodiments, cement or otherpourable or moldable building materials may also be used. In otherembodiments, any combination of suitable building material may becombined by using one building material for some components of thebalcony and other building materials for other components of thebalcony. Selection of any material may be made from a reference ofmaterial options (such as those provided for in the InternationalBuilding Code), or selected based on the knowledge of those of ordinaryskill in the art when determining load bearing requirements for thestructures to be built. Larger and/or taller structures may have greaterphysical strength requirements than smaller and/or shorter buildings.Adjustments in building materials to accommodate size of structureand/or load and environmental stresses can determine optimal economicalchoices of building materials used for all components in the balconydescribed herein. Availability of various building materials indifferent parts of the world may also affect selection of materials forbuilding the system described herein. Adoption of the InternationalBuilding Code or similar code may also affect the selection ofmaterials.

Any reference herein to “metal” includes any construction grade metalsor metal alloys as may be suitable for fabrication and/or constructionof the balcony and components described herein. Any reference to “wood”includes wood, wood laminated products, wood pressed products, woodpolymer composites (WPCs), bamboo or bamboo related products, ligninproducts, and/or any plant derived product, whether chemically treated,refined, processed or simply harvested from a plant. Any referenceherein to “concrete” includes any construction grade curable compositethat includes cement, water, and a granular aggregate. Granularaggregates may include sand, gravel, polymers, ash and/or otherminerals.

In general, in some implementations, a balcony system or false balconysystem may be manufactured and installed in a method that includesmanufacturing and assembling portions of the balcony or false balconyoff-site from a construction site and delivering to the constructionsite a partially built balcony and kit of part to finish installationand assembly on-site at the construction site. For example, a steelfabricator may make a balcony beam and weld a channel member to thebeam. The channel member can include a light gauge “c” section withholes punched at a given interval (e.g., 12 inches), where the holes arepunched for rebar (reinforcing bar) to be inserted during the balconyfloor manufacturing process. A balcony frame can be fabricated fromrolled stainless steel.

The balcony beam and frame can be delivered to a concrete precast shop.At the precast shop, rebar (or reinforcing bar) is inserted into theholes in the channel welded to the balcony beam. The balcony beam andbalcony frame can be placed into form that holds the beam and frame andpermits the rebar to be inserted into the holes in the channel member.Also, guardrail support members can be installed and secure to thebalcony frame. The form can then be poured with concrete (or othermaterial suitable for casting). Once the concrete cures, it secures thebalcony beam to the balcony frame and creates an integral balconyassembly. Also, the guardrail support members are secured in place bythe cured concrete.

Some implementations can include a guardrail having horizontal membersto which the glazing for the balcony guardrail can be attached. Byproviding horizontal members for the glazing to attach to, the balconysystem and false balcony system described herein permit the glazingpieces to be standardized and not limited to attaching to the guardrailstanchion supports (e.g., vertical posts). This provides an advantage ofpermitting standardized guardrail stanchion support spacing because theglazing is not tied directly to the stanchion supports.

Turning now to the drawings, FIGS. 1-3 are diagrams of an examplebalcony system 100 in accordance with some embodiments. The balconysystem 100 is attached to two structural frame members (e.g., wideflange columns) 102 and 104.

The balcony system 100 includes two groups of components. A first groupof components may be manufactured and assembled offsite (e.g., not on abuilding construction site where the balcony system 100 is to beinstalled). A second group of components (including guardrailcomponents) may be installed on the balcony system 100 at theconstruction site.

The first group of components includes a balcony beam 112, a channelbalcony frame 114, one or more reinforcing bars 116, a precast concretebalcony floor 118, a balcony beam attachment member 120, and one or moreguardrail support brackets 122. In an example embodiment, the metalcomponents (e.g., 112, 114, 116, 120, and 122) may be manufactured andassembled (or partially assembled) at a metal fabrication facility. Theassembled or partially assembled metal components may then be sent to aconcrete casting facility that pours and casts the concrete balconyfloor 118. The concrete balcony floor 118, once cured, secures the metaland concrete components together into an integral balcony unit that canbe delivered to a construction site for use on a building.

Along with the integral balcony unit, the second group of components maybe delivered to the construction site for use in final assembly of thebalcony. The second group of components can include a guardrail 106,which may be a single piece or may be a multi-piece guardrail. Thesecond group of components can also include one or more stanchionguardrail supports 108, one or more guardrail panels 110, and one ormore sets of hardware including one or more closure plates 124 to attachthe one or more stanchion guardrail supports 108 to correspondingguardrail support brackets 122.

At the construction site, the integral balcony unit can be installed onthe building structure. For example, the balcony system 100 includes abalcony beam 112 having a first end and a second end. The first end ofthe balcony beam 112 is attached to a corresponding first structuralframe member 102 and the second end of the balcony beam is attached to acorresponding second structural frame member 104. The attachment can bemade via a plate at each of the first end and the second end of thebalcony beam 112 that can be bolted or otherwise attached to thestructural frame members 102 and 104.

Once the integral balcony unit is installed, the second group of balconycomponents can be installed for final assembly of the balcony system.Once the balcony guardrail 106 is in place, the risk of falling out ofthe balcony opening is substantially reduced. Thus, a need orrequirement for use of safety harnesses within the room or area of thebuilding having the balcony system may be removed and workers mayproceed to work with greater safety and efficiency within the room orarea by performing such tasks as interior wall construction, electricalconnections, mechanical connections, and finishing without having towear a safety harness.

As shown in FIG. 3, the second group of components (e.g., the guardrailcomponents) can include horizontal members 302 that are attached to thestanchion guardrail supports 108. The guardrail panels 110 can beattached to the horizontal members 302.

The balcony beam 112 and the channel balcony frame 114 can be formedfrom stainless steel in one embodiment. The guardrail support brackets122 can include an angle bracket that is attached to the channel balconyframe 114 via a bolt system (e.g., a 5 inch bolt) extending into aninterior space defined by the channel balcony frame 114 and held inplace by the concrete balcony floor 118.

FIGS. 4-6 are diagrams showing a side sectional view, a top plan view,and a front elevation view, respectively, of a guardrail connection inaccordance with some embodiments. The connection includes bolts 402 and404 (e.g., 5 inch bolts) that attach the guardrail support bracket 122(which can be an angled guardrail support bracket) to the channelbalcony frame 114 and that are secured in place by hardware (e.g., anut, a washer, etc.) and the cured concrete balcony floor 118. Theangled guardrail support bracket 122 is used to support and attach thestanchion guardrail support 108 to the chancel balcony frame 114.

FIG. 7 is a diagram showing a false balcony system 700 in accordancewith some embodiments. The false balcony system 700 includes a guardrail702, one or more stanchion guardrail supports 704, one or more guardrailpanels 706, a horizontal guardrail member 708, an optional light 710(e.g., a continuous LED light strip), a “Z” break-shape balcony beamattachment member 712, one or more guardrail support brackets 714, and abalcony beam 716.

The “Z” break-shape balcony beam attachment member 712 is attached(e.g., welded or otherwise fastened or coupled) to the balcony beam 716.The guardrail support brackets 714 are attached to the “Z” break-shapebalcony beam attachment member 712.

FIG. 8 is a diagram showing a balcony system 800 in accordance with someembodiments. The balcony system 800 includes a guardrail 802, one ormore stanchion guardrail supports 804, one or more guardrail panels 806,a horizontal guardrail member 808, an optional light 810 (e.g., acontinuous LED light strip), a channel balcony frame 812, one or moreguardrail support brackets 814, one or more bolts 816 (attaching theguardrail support brackets 814 to the channel balcony frame 812), a castconcrete balcony floor 818, a balcony beam attachment member 820(connected to the reinforcing members and cast into the concrete balconyfloor), a balcony beam 822 (attached to the balcony beam attachmentmember 820), and one or more channel balcony frame attachment bolts 824(securing the channel balcony frame 812 into the concrete balcony floor818). A thermal break is provided between the cast concrete balconyfloor 818 and the building.

FIG. 9 is a diagram showing an example building with false balconies 700and balconies 800 in accordance with some embodiments. A building caninclude zero or more false balconies 700 and zero or more balconies 800.

FIGS. 10A, 10B, and 10C show elevation, plan and framing views,respectively, of an example studio unit balcony with metal infill inaccordance with some implementations. In particular, FIG. 10A shows astructural column 1002 coupled to a balcony support member 1004 (e.g., a6″×10″ tubular steel member), which supports the balcony and aligns andspaces the balcony and structural columns. The balcony includes asloping steel bar top 1016 (e.g., ½″×3-½″) with factory-weldedconnections to vertical stanchions 1012 that fit into punch holes 1014(e.g., holes punched 3′ on center) in the balcony frame and are boltedto the balcony frame (e.g., 2204). The balcony further includeshorizontal members 13 (e.g., 1-½″×1-½″×2-½″ t-slot extrusion membersfactory welded to the vertical stanchions) that the guardrail panels1020 are attached to. The guardrail panels of FIG. 10A or other figuresherein can include one or more of tempered glass, 3Form, metal mesh,polycarbonate, and/or photovoltaic panels. The balcony can also includea factory installed decking panel(s) 1026. The decking panel(s) 1026 caninclude any suitable decking material such as synthetic material, tile,wood, etc. Details of the section indicated by Si in FIG. 10A are shownin FIG. 19.

As shown in FIG. 10B, the balcony frame can be coped and welded at thetubular steel support 1006. Also shown in FIG. 10B continuous Z-breakshape members (e.g., 2″×2-⅛″×2″×2″) having deck hold down clips andbeing factory-bolted to the balcony frame.

FIG. 10C shows metal infill including one or more of c-channel members1008 (e.g., 4″×1.76″ steel c channel) factory-welded to tubular steelmember 1004, break-shape channel 2204, steel plates 1010 (e.g., ¼″ steelplates), and metal studs (e.g., 2-½″ and 4″) 1022 factory attached tothe c-channel members 1008.

FIGS. 11A, 11B, and 11C; and 12A, 12B, and 12C show elevation, plan andframing views, respectively, of example studio unit balconies with metalinfill with features similar to those shown in FIGS. 10A-10C. Theexample balconies shown in FIGS. 11A-C and 12A-C differ in terms ofdimensions and/or number of components.

FIGS. 13A, 13B, and 13C; 14A, 14B, and 14C; and 15A, 15B, and 15C showelevation, plan and framing views, respectively, of example one bedroomunit balconies with metal infill with features similar to those shown inFIGS. 10A-10C. The example balconies shown in FIGS. 13A-C, 14A-C, and15A-C differ from that shown in FIGS. 10A-C in terms of dimensionsand/or number of components.

FIGS. 16A, 16B, and 16C show elevation, plan and framing views,respectively, of an example one bedroom unit balcony with metal infillwith features similar to those shown in FIGS. 10A-10C. In addition tothe feature shown in FIGS. 10A-C, FIGS. 16A and B also show decorativepanels 1602 (e.g., PVC panels) attached to the balcony.

FIGS. 17A, 17B, and 17C show elevation, plan and framing views,respectively, of an example two bedroom unit balcony with metal infillwith features similar to those shown in FIGS. 10A-10C. In addition tothe feature shown in FIGS. 10A-C, FIGS. 17A and B also show decorativepanels 1702 (e.g., PVC panels) attached to the balcony.

FIGS. 18A, 18B, and 18C show elevation, plan and framing views,respectively, of an example two bedroom unit balcony with metal infillwith features similar to those shown in FIGS. 10A-10C. In addition tothe feature shown in FIGS. 10A-C, FIGS. 18A and B also show decorativepanels 1802 (e.g., PVC panels) attached to the balcony.

FIG. 19 is a sectional view (denoted 51 in earlier figures) of anexample balcony with metal infill in accordance with someimplementations. In particular, FIG. 19 shows a tubular steel balconysupport member 1902 (e.g., a 6″×10″ tubular steel member similar to 1004in FIG. 10A), vertical stanchions 1904, horizontal member 1908 withangle welded to vertical stanchions and T-slot extruded member 1906attached to the angle, guardrail panels 1910, optional continuous lightstrip 1912 (e.g., continuous LED light strip). The balcony also includesa deck including cement board 1914, waterproof membrane 1916, anddecking 1920 (e.g., composite decking material) installed on top of themetal infilled balcony frame, with sheathing 1918 applied to anunderside of the metal infilled balcony frame. FIG. 19 also showsrelationship of the balcony to the corbel beam 1922, including a gapbetween the balcony and corbel beam 1922.

FIG. 20 is a sectional view of an example balcony with metal infill inaccordance with some implementations. In particular, FIG. 20 shows atubular steel balcony support member 2002 (e.g., a 6″×10″ tubular steelmember similar to 1004 in FIG. 10A), sloping steel member 2004 factorywelded to vertical stanchions, horizontal member 2008 with angle weldedto vertical stanchions and T-slot extruded member 2006 attached to theangle, guardrail panels 2010, optional continuous light strip 2012(e.g., continuous LED light strip). The balcony also includes a deckincluding cement board 2014, waterproof membrane 2016, and decking 2020(e.g., composite decking material) installed on top of the metalinfilled balcony frame, with sheathing 2018 applied to an underside ofthe metal infilled balcony frame. FIG. 20 also shows relationship of thebalcony to the corbel beam 2022, including a gap between the balcony andcorbel beam 2022. FIG. 20 further shows a decorative panel 2024 (e.g., aPVC panel) attached to the sloping member 2004.

FIG. 21 is a sectional view of an example false balcony with metalinfill in accordance with some implementations. FIG. 21 shows a slopingsteel bard top 2106 factory welded to vertical stanchions 2104.Guardrail panels 2108 are attached to the vertical stanchions 2104attached to balcony frame member 2106 that is factory welded to thebalcony support beam 2102.

FIG. 22 shows sectional details (D1-D4) of an example balcony with metalinfill in accordance with some implementations. As shown in FIG. 22, abalcony frame 2204 is attached to a balcony beam 2202. The balconyincludes metal infill members such as c-channel members 2206 factorywelded to the balcony beam 2202 and balcony frame 2204.

The balcony includes a plurality of flat bar vertical stanchions 2214that are bolted to guardrail support member 2208, which isfactory-welded to the balcony frame 2204. The connection of thestanchions 2214 to the guardrail support member 2208 is reinforced by aclosure plate 2210. Shim plates 2212 can be used in the stanchion 2214to guardrail support member 2208 connection as needed.

As mentioned above, a metal infilled balcony can include metal studs2216 attached (e.g., factory welded) to the c-channel members 2206.

The balcony deck shown in FIG. 22 includes a waterproof membrane 2218,composite decking sleeper 2226 (e.g., 1″×3″ class A fire rated),composite decking 2224 (e.g., 1″×6″ class A fire rated), steel plate2220 (e.g., ¼″ steel plate factory welded to c-channel members 2206),and steel plate 2228 (e.g., ¼″ steel plate factory welded to balconyframe and c-channel members with water-tight welds). An interior of thebalcony can include factory-installed fire insulation 2230, one or morelayers of sheathing 2222 (e.g., two layers of Densglass sheathing), andfire rated rod and sealant 2232.

FIG. 23 is a flowchart of an example method to make and install abalcony system in accordance with some embodiments. The variousoperations of the methods described herein need not necessarily beperformed in the exact order as shown. Moreover, some operations may beadded, removed, modified, and/or combined together. The method may beginat 2302, where a balcony beam is formed. In some implementations, thebalcony beam can be formed from tube steel and prefinished (e.g.,finished at manufacture time and prior to installation in a building).In some implementations, the balcony beam can be a precast element thatis formed and poured with the concrete deck as a single piece, whichwould eliminate a need for the tube steel balcony beam. The methodcontinues to 2304.

At 2304, the channel balcony frame is formed. For example, the channelbalcony frame can be formed from rolled stainless steel. The methodcontinues to 2306.

At 2306, the channel balcony frame is attached to the balcony beam. Forexample, a balcony beam attachment member (e.g., 820) is attached to thebalcony beam (e.g., by welding or other attachments) and one or morereinforcing bars or members can be connected to the balcony beamattachment member. The method continues to 2308.

At 2308, one or more guardrail support brackets are attached to thechannel balcony frame. For example, bolts (e.g., 816) are used to attachthe guardrail support brackets to the channel balcony frame, where thebolts extend into an interior space defined by the channel balconyframe. The method continues to 2310.

At 2310, the concrete balcony floor is cast within the interior spacedefined by the balcony channel frame. The concrete balcony floor, oncecured, helps secure the channel balcony frame, the guardrail supportbrackets, the reinforcing members, the balcony beam attachment member,and the balcony beam into an integral balcony unit (or balcony deck).The method continues to 2312.

At 2312, the balcony deck and railing parts are provided to aconstruction site. The method continues to 2314.

At 2314, the balcony deck or integral balcony unit is attached to abuilding. For example, the balcony beam is attached at each end to arespective structural frame member (e.g., a wide flange metal column).Attaching the integral balcony unit can serve to attach the integralbalcony unit to the structure and can also help align the structuralmembers (e.g., wide flange columns). The method continues to 2316.

At 2316, the guardrail is attached to the integral balcony unit. Forexample, the stanchion guardrail supports can be attached to theguardrail support brackets. The guardrail can be attached to thestanchion guardrail supports. The horizontal guardrail members can beattached to the stanchion guardrail supports. The method continues to2318.

At 2318, the guardrail panels can be attached to the horizontalguardrail members.

FIG. 24 is a flowchart of an example method for making and installing afalse balcony system in accordance with some embodiments. The methodbegins at 2402, where a balcony beam is formed. In some implementations,the balcony beam can be formed from tube steel and prefinished (e.g.,having a finished applied prior to being installed in a building). Themethod continues to 2404.

At 2404, a “Z” break-shape member (or balcony beam attachment member) isformed. For example, the “Z” break-shape member can be formed fromrolled stainless steel. The method continues to 2406.

At 2406, the “Z” break-shape member is attached to the balcony frame.For example, a balcony beam attachment member (e.g., 712) is attached tothe balcony beam (e.g., by welding or other attachments) and one or morereinforcing bars or members can be connected to the balcony beamattachment member. The method continues to 2408.

At 2408, one or more guardrail support brackets are attached to thebalcony beam attachment member. The method continues to 2410.

At 2410, the balcony beam and railing parts are provided to aconstruction site. The method continues to 2412.

At 2412, the balcony beam is attached to a building. For example, thebalcony beam is attached at each end to a respective structural framemember (e.g., a wide flange metal column). Attaching the balcony beamcan serve to attach the false balcony unit to the structure and can alsohelp align the structural members (e.g., wide flange columns). Themethod continues to 2414.

At 2414, the guardrail is attached to the integral balcony unit. Forexample, the stanchion guardrail supports can be attached to theguardrail support brackets. The guardrail can be attached to thestanchion guardrail supports. The horizontal guardrail members can beattached to the stanchion guardrail supports. The method continues to2416.

At 2416, the guardrail panels can be attached to the horizontalguardrail members.

The balcony may be attached to the frame of a building, for example toan external structural frame, via one or more plates bolted to a wideflange column. For example, the balcony may be attached to an exteriorsteel structure, which may provide the structural support and/oralignment for a building. Generally, any mechanism may be used to attachthe balcony to the frame of the building, such as an external steelstructure. Any type of fastening may generally be used. In someembodiments, the balcony may be coupled to a vertical or horizontal beamincluded in the frame of the building.

Concrete may be poured onto the floor and ceiling panel. Pouring theconcrete may form a floor of the balcony. In some embodiments, thebalcony may transmit lateral loads to the lateral load system of thebuilding. In this manner, the concrete may be poured at the completedheight of the story of the building, after the floor and ceiling panelshave been positioned at the desired story, thereby forming the floor ofunits in that story. In some embodiments, the balconies are installedafter the concrete has cured on the floor and ceiling panels.

Embodiments of balcony and false balcony systems may provide a floor andceiling system useable in mid-rise and high-rise residential projects,among others. The panels with or without the closure pieces and tracksinstalled may be configured to comply with one or more of the followingbuilding codes: fire, energy, handicap, life-safety, and acoustical(impact and ambient noise transfer). In some embodiments, thepre-assembled floor and ceiling panels with or without the closurepieces and tracks may be considered as a fully-integrated sub-assemblymeeting fire, sound impact, energy, and life/safety codes. The floor andceiling panels may be fully integrated with electrical, fire protection,energy insulation, and sound isolation capabilities in some embodiments.The floor and ceiling panels may be designed to achieve a fire ratingset by the applicable building code, such as a two-hour fire rating.

The balconies described herein may be fabricated off-site in a factoryor shop and transported to the construction site (building site) forattachment to a structural frame, such as a structural exoskeleton, of abuilding. A balcony system or false balcony system, or componentsthereof, may be fabricated in various sizes, such as 8 feet to 10 feetin width up to 22 feet in width. At the building site, the balcony maybe attached to structural frame members, floor and ceiling panels, endwalls, demising walls, utility panels, building utilities, or anycombination thereof. The structural frame members may provide supportfor the balcony, which may include a concrete slab poured off-site in acasting facility or on-site. In some embodiments, the balcony transfersloads to the structural frame members. In some embodiments, the balconytransfers loads directly to a steel structure of the building, and thebalcony does not translate loads from the floor and ceiling panel to thestructure. In some embodiments, the balcony may be non-load bearing(e.g., in the case of a false balcony).

The examples provided herein are for explanatory purposes only andshould not be considered to limit the scope of the disclosure. Eachexample embodiment may be practical for a particular environment such asurban mixed-use developments, low-rise residential units, and/or remotecommunities. Materials and dimensions for individual elements may beselected to comply with one or more of the following building codes:fire, energy, handicap, life-safety, and acoustical (impact and ambientnoise transfer) without departing from the scope of the principles ofthe disclosure. The elements and/or system may also be configured tocomply with social and/or religious codes as desired. For example,materials, systems, methods, and/or apparatuses may be configured tocomply with the International Building Code as it has been adopted in ajurisdiction.

The present disclosure is not to be limited in terms of the particularembodiments described in this application, which are intended asillustrations of various aspects. Many modifications and embodiments canbe made without departing from its spirit and scope. Functionallyequivalent methods and apparatuses within the scope of the disclosure,in addition to those enumerated herein, are possible from the foregoingdescriptions. Such modifications and embodiments are intended to fallwithin the scope of the appended claims. The present disclosure is to belimited only by the terms of the appended claims, along with the fullscope of equivalents to which such claims are entitled. This disclosureis not limited to particular methods, which can, of course, vary. Theterminology used herein is for the purpose of describing particularembodiments only, and is not intended to be limiting.

With respect to the use of substantially any plural and/or singularterms herein, the terms can be translated from the plural to thesingular and/or from the singular to the plural as is appropriate to thecontext and/or application. The various singular/plural permutations maybe expressly set forth herein for sake of clarity.

In general, terms used herein, and especially in the appended claims(e.g., bodies of the appended claims) are generally intended as “open”terms (e.g., the term “including” should be interpreted as “includingbut not limited to,” the term “having” should be interpreted as “havingat least,” the term “includes” should be interpreted as “includes but isnot limited to,” etc.).

If a specific number of an introduced claim recitation is intended, suchan intent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to embodiments containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should be interpreted to mean “at least one”or “one or more”); the same holds true for the use of definite articlesused to introduce claim recitations. In addition, even if a specificnumber of an introduced claim recitation is explicitly recited, suchrecitation should be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, means at least two recitations, or two or more recitations).

Furthermore, in those instances where a convention analogous to “atleast one of A, B, and C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, and C”would include but not be limited to systems that have A alone, B alone,C alone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). In those instances where a conventionanalogous to “at least one of A, B, or C, etc.” is used, in general sucha construction is intended in the sense one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, or C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). Virtually any disjunctiveword and/or phrase presenting two or more alternative terms, whether inthe description, claims, or drawings, should be understood tocontemplate the possibilities of including one of the terms, either ofthe terms, or both terms. For example, the phrase “A or B” will beunderstood to include the possibilities of “A” or “B” or “A and B.”

In addition, where features or aspects of the disclosure are describedin terms of Markush groups, the disclosure is also thereby described interms of any individual member or subgroup of members of the Markushgroup.

For any and all purposes, such as in terms of providing a writtendescription, all ranges disclosed herein also encompass any and allpossible subranges and combinations of subranges thereof. Any listedrange can be easily recognized as sufficiently describing and enablingthe same range being broken down into at least equal halves, thirds,quarters, fifths, tenths, etc. As a non-limiting example, each rangediscussed herein can be readily broken down into a lower third, middlethird and upper third, etc. Language such as “up to,” “at least,”“greater than,” “less than,” and the like include the number recited andrefer to ranges which can be subsequently broken down into subranges asdiscussed above. A range includes each individual member. Thus, forexample, a group having 1-3 items refers to groups having 1, 2, or 3items. Similarly, a group having 1-5 items refers to groups having 1, 2,3, 4, or 5 items, and so forth.

The herein described subject matter sometimes illustrates differentcomponents contained within, or connected with, different othercomponents. Such depicted architectures are merely embodiments, and infact many other architectures can be implemented which achieve the samefunctionality. In a conceptual sense, any arrangement of components toachieve the same functionality is effectively “associated” such that thedesired functionality is achieved. Hence, any two components hereincombined to achieve a particular functionality can be seen as“associated with” each other such that the desired functionality isachieved, irrespective of architectures or intermedial components.Likewise, any two components so associated can also be viewed as being“operably connected”, or “operably coupled”, to each other to achievethe desired functionality, and any two components capable of being soassociated can also be viewed as being “operably couplable”, to eachother to achieve the desired functionality. Specific embodiments ofoperably couplable include but are not limited to physically mateableand/or physically interacting components.

While various aspects and embodiments have been disclosed herein, otheraspects and embodiments are possible. The various aspects andembodiments disclosed herein are for purposes of illustration and arenot intended to be limiting.

1. A balcony system, comprising: a balcony beam including a first endand a second end, wherein each of the first end and the second end areconfigured to attach to corresponding structural frame members of abuilding; a channel balcony frame; a balcony beam attachment memberattached to the balcony beam and having one or more apertures; one ormore reinforcement bars disposed in an interior space defined by thechannel balcony frame, wherein the one or more reinforcement bars extendthrough the one or more apertures in the balcony beam attachment member,and wherein the reinforcement bars and the balcony beam attachmentmember are held in place within the interior space defined by thechannel balcony frame by a balcony floor formed within the interiorspace defined by the channel balcony frame, such that, after the flooris formed, the balcony beam, channel balcony frame, and balcony floorform an integral unit; one or more guardrail support brackets attachedto the channel balcony frame via one or more fasteners that pass throughthe one or more guardrail support brackets and into the interior spacedefined by the channel balcony frame, wherein the one or more guardrailsupport brackets are secured in place by the balcony floor formed withinthe interior space defined by the channel balcony frame; one or morestanchion guardrail supports each attached to a respective one of theone or more guardrail support brackets and secured in place by acorresponding closure plate; a guardrail attached to the one or morestanchion guardrail supports; one or more horizontal guardrail membersattached to the one or more stanchion guardrail supports; and one ormore guardrail panels attached to the one or more horizontal guardrailmembers.
 2. The balcony system of claim 1, wherein each of the first endand the second end include a respective plate to couple the balcony beamto the corresponding structural frame members of the building.
 3. Thebalcony system of claim 1, wherein the channel balcony frame has arectangular shape.
 4. The balcony system of claim 1, wherein the channelbalcony frame includes one or more stanchion guard rail supportapertures each configured to enable a respective stanchion guard railsupport to pass through a respective stanchion guard rail supportaperture.
 5. The balcony system of claim 1, wherein the channel balconyframe is formed from stainless steel and the balcony floor is formedfrom concrete.
 6. The balcony system of claim 1, further comprising alight element coupled to the one or more stanchion guardrail supports.7. The balcony system of claim 1, wherein the one or more guardrailpanels include one or more of tempered glass, metal mesh, polycarbonate,photovoltaic panels, or resin panels.
 8. A false balcony system,comprising: a balcony beam including a first end and a second end,wherein each of the first end and the second end are configured toattach to corresponding structural frame members of a building; abalcony beam attachment member attached to the balcony beam such thatthe balcony beam attachment member and the balcony beam form an integralunit, wherein the balcony beam attachment member includes one or moreapertures; one or more guardrail support brackets attached to thebalcony beam attachment member via one or more fasteners that passthrough the one or more guardrail support brackets and through arespective aperture in the balcony beam attachment member; one or morestanchion guardrail supports each attached to a respective one of theone or more guardrail support brackets and secured in place by acorresponding closure plate; a guardrail attached to the one or morestanchion guardrail supports; one or more horizontal guardrail membersattached to the one or more stanchion guardrail supports; and one ormore guardrail panels attached to the one or more horizontal guardrailmembers.
 9. The false balcony system of claim 8, wherein each of thefirst end and the second end include a respective plate to couple thebalcony beam to the corresponding structural frame members of thebuilding.
 10. The false balcony system of claim 8, further comprising alight element coupled to the one or more stanchion guardrail supports.11. The false balcony system of claim 8, wherein the guardrail panelsinclude one or more of tempered glass, metal mesh, polycarbonate,photovoltaic panels, or resin panels.
 12. A method to make and install abalcony system, the method comprising: forming a balcony beam having afirst end and a second end; forming a channel balcony frame; forming abalcony beam attachment member; attaching the balcony beam attachmentmember to the balcony beam; attaching guardrail support brackets to thechannel balcony frame; forming a balcony floor within a space defined bythe channel balcony frame to form an integral balcony unit that includesthe balcony beam, the channel balcony frame, and the balcony floor;providing the integral balcony unit and guardrail parts to aconstruction site of a building, wherein the guardrail parts include aguardrail and one or more stanchion guardrail supports; attaching theintegral balcony unit to a structural frame of the building; attachingthe guardrail parts to the integral balcony unit; and attaching one ormore guardrail panels to the guardrail.
 13. The method of claim 12,further comprising attaching a respective plate to each of the first endand the second end of the balcony beam to couple the balcony beam to thestructural frame of the building.
 14. The method of claim 12, whereinforming the channel balcony frame comprises forming the channel balconyframe in a rectangular shape.
 15. The method of claim 12, wherein thechannel balcony frame includes one or more stanchion guard rail supportapertures each configured a respective stanchion guard rail support topass through a respective stanchion guard rail support aperture.
 16. Themethod of claim 12, wherein forming the channel balcony frame comprisesforming the channel balcony frame from stainless steel.
 17. The methodof claim 12, wherein the guardrail panels include one or more oftempered glass, metal mesh, polycarbonate, photovoltaic panels, or resinpanels.
 18. A method to make and install a false balcony system, themethod comprising: forming a balcony beam having a first end and asecond end; forming a balcony beam attachment member; attaching thebalcony beam attachment member to the balcony beam to form an integralbalcony unit; providing the integral balcony unit and guardrail parts toa construction site of a building, wherein the guardrail parts include aguardrail and one or more stanchion guardrail supports; attaching theintegral balcony unit to a structural frame of the building; attachingthe guardrail parts to the integral balcony unit; and attaching one ormore guardrail panels to the guardrail.
 19. The method of claim 18,further comprising attaching a respective plate to each of the first endand the second end of the balcony beam to couple the balcony beam to thestructural frame of the building.
 20. The method of claim 18, whereinthe guardrail panels include one or more of tempered glass, metal mesh,polycarbonate, photovoltaic panels, or resin panels.